Introduction: How to Make Your Own Letters Using Styrofoam and Wood

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In this project, I will talk about how to make your own letters using styrofoam and wood. It is an easy way to make your letters, names, logos, ...etc using styrofoam and wood, also you can customize them as you want.

Also, you can see the Instructables in an amazing video on YouTube, please If you liked this video, make sure to subscribe for more!



  • Styrofoam 6cm thickness
  • MDF wood 2.5 mm thickness
  • Wood glue
  • Spray paint
  • Accessories (Pearls, Diamonds)
  • Hot glue
  • Sandpaper

Step 1: Making the Design

I used Adobe illustrator for making this design, you can do what you want it is up to you.

I exported the design to the DXF file, that it is suitable for CNC cut.

Step 2: Cutting MDF Wood

You can cut the design directly with Styrofoam, but I prefer to cut two pieces of wood to make them as a guide to get a perfect cut with a hot wire foam cutter.

I used my router CNC to cut the design, but you can also cut it using a hand saw.

Step 3: Cutting Styrofoam

I used two layers of foam to get 6 cm thickness, but I prefer to use one thick layer instead.

I cut the foam using my hot wire foam cutter, you can see the full Instructables of making foam cutter here and in a video on YouTube.

Step 4: Make It Ready for Paint

I refined the foam letter to make it smoother using sandpaper 220, then applied a prime coat from wood glue to make stronger and to protect the foam letter from the spray paint, because spray paint can damage and melt the foam.

You can paint the foam directly without a prime coat if you are using acrylic paint.

Step 5: Decorating the Letter

There are many ways to decorate the letter, it is up to you.

I used pearls and diamonds in different sizes and glue them using hot glue.

Step 6: Give It a Perfect Place

Finally, I got perfect results, it is so beautiful and cute.

I found this way to make 3d letters, names, logos, ..etc very easy and can anyone do it yourself, if anyone has a better idea for making something like that plz tell me.

It is really amazing, and it is a perfect gift for babies.